Flat-web roller blind cover

ABSTRACT

A roller blind cover for an aperture in a vehicle interior. The roller blind cover has a carrier layer, a decorative layer, and a coating that covers the visible surface of the decorative layer. The overlay coating may be elastic with a layer thickness of at least 0.3 mm. The overlay coating may be permanently bonded to the visible surface of the decorative layer.

CROSS REFERENCE TO RELATED APPLICATION

Foreign priority benefits are claimed under 35 U.S.C. §119(a)-(d) or 35U.S.C. §365(b) of German Application No. 10 2005 050 825.1, filed Oct.24, 2005, which is hereby incorporated by reference in its entirety.

BACKGROUND

1. Field

The present invention relates to a roller blind cover for an aperture,and more particularly to a flat-web roller blind cover for an aperturein the interior of a vehicle.

2. Discussion of Related Art

Roller blind covers, such as flat-web roller blind covers, are generallyknown in the art for use in vehicles. For example, roller blind coverscan be used to cover stowage compartments, such as described in DE 202004 006 649.1. Such roller blind covers usually have a single ormulti-ply carrier layer that is flexible in only one plane. The carrierlayer serves as the supporting structure of the roller blind cover. Inuse, the carrier layer is typically guided along opposed longitudinaledges by sliding block guides that lie along opposed edges of theaperture that is being covered.

The carrier layer used in prior art roller blinds is typically a simple,flexible plastic or sheet steel plate that may be reinforced withcrosswise ribs, a woven wire and/or textile fabric.

The carrier layer is often covered with a decorative layer to provide adesired appearance for the roller blind. Decorative layers are knownthat comprise layers of textile material, carbon, plastic, and leather.The choice of such decorative layers has been limited to materials withgrain, layer thickness, and elasticity that are capable of withstandingthe bending and stretching strains that are incurred when used in rollerblind covers constructed according to the prior art.

A protective lacquer layer, typically only a few microns thick, is oftenapplied to the visible surface of the decorative layer.

There is a need in the art for a roller blind cover design that allowsthe use of hard and/or less flexible materials as a decorative layer.

SUMMARY

According to one aspect of the invention a roller blind cover for anaperture in a vehicle interior is disclosed. The roller blind covercomprises a carrier layer and a decorative layer. The decorative layerhas a visible surface and is attached to the carrier layer. An overlaycoating covers the decorative layer and provides a view of the visiblesurface. The overlay coating is permanently bonded to the visiblesurface and has a thickness of at least 0.3 mm.

According to another aspect of the invention a roller blind cover for avehicle interior is disclosed. The roller blind cover comprises acarrier layer, a decorative layer, and an overlay coating. Thedecorative layer is positioned between the carrier layer and the overlaycoating and lies along a neutral axis of the roller blind cover when theroller blind cover is flexed during use.

Also disclosed is a method of forming a roller blind cover for a vehicleinterior. The method comprises providing a carrier layer. The methodalso comprises providing a decorative layer that comprises decorativematerial that is less elastic than the carrier layer. The decorativematerial is coupled to an intermediate layer of the decorative layer.The decorative layer is rendered more flexible while the decorativematerial is held by the intermediate layer. The method also comprisesassembling the decorative layer to the carrier layer.

Various embodiments of the present invention provide certain advantages.Not all embodiments of the invention share the same advantages and thosethat do may not share them under all circumstances.

Further features and advantages of the present invention, as well as thestructure of various embodiments of the present invention are describedin detail below with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are not intended to be drawn to scale. In thedrawings, each identical or nearly identical component that isillustrated in various figures is represented by a like numeral. Forpurposes of clarity, not every component may be labelled in everydrawing. Various embodiments of the invention will now be described, byway of example, with reference to the accompanying drawings, in which:

FIG. 1 shows a perspective view of a flat-web roller blind coveraccording to one embodiment of the invention; and

FIG. 2 shows a schematic cross-sectional view of the flat-web rollerblind cover shown in FIG. 1.

DETAILED DESCRIPTION

Aspects of the present invention provide a roller blind cover that maybe used to cover an aperture in the interior of a vehicle. Embodimentsof the roller blind cover enable the decorative layer of the rollerblind to be made of hard and/or less flexible materials.

Broadly speaking, illustrative embodiments of the roller blind coverinclude a carrier layer that may ride in sliding block guides positionedon opposed lateral edges of an aperture. The aperture may lie in theinterior of a vehicle. A decorative layer may be positioned on top ofthe carrier layer and may comprise a thickness that is greater than thatused in prior art roller blind covers. An overlay may be placed on topof the decorative layer to provide protection while allowing thedecorative layer to be viewed. The thickness and mechanicalcharacteristics of each of the carrier layer, the decorative layer, andthe overlay layer, along with any other intermediate layers, may beconfigured such that the decorative layer lies on or near the neutralaxis of the roller blind cover when flexed during use to open and closethe aperture. In this regard, the decorative layer may be subjected tofewer strains and/or stresses, which enables the use of a wider varietyof materials.

According to some illustrative embodiments, the roller blind coverenables hard and/or less flexible materials to be used as a decorativelayer. In some embodiments, the decorative layer is less elastic thanone or both of the carrier layer and/or an overlay layer of the rollerblind cover.

In some embodiments, the overlay layer may be elastic. The overlay layermay also have a thickness of at least 0.3 mm, or at least 0.5 mm, or atleast 1.0 mm, or at least 2.0 mm, or at least 3.0 mm or even greaterthicknesses, as aspects of the invention are not limited in thisrespect. Overlay layers may also be permanently bonded to the visiblesurface of the decorative layer, although they are not required to be,as aspects of the invention are not limited in this respect.

The decorative layer, according to illustrative embodiments, may besandwiched between the carrier layer and an overlay layer to form alayered laminate. In the layered laminate, the decorative layer may bepositioned close to or centered on the neutral axis of the roller blindcover. The neutral axis, as the term is used herein, refers to the lineor plane along which minimal or no strain occurs when the roller blindcover is flexed about a curved surface during use. In many embodiments,the neutral line or plane will be positioned between areas thatexperience tension and areas that experience compression when the rollerblind cover is flexed about the curved surface.

The decorative layer may have different thicknesses according todifferent embodiments of the invention. In some embodiments, thedecorative layer has a thickness of 0.2 mm. Still, in other embodiments,the decorative layer has a thickness of about 1.5 mm. It is to beappreciated that other thicknesses are a possible, such as those thatlie between 0.2 mm and 1.5 mm, or thicknesses that lie outside of thisrange of thicknesses, as the present invention is not limited in thisrespect.

The overlay layer may comprise various types of material. In someillustrative embodiments, the overlay layer is chosen for its elasticproperties. The overlay material may also have optical properties thatallow or even enhance an external view of the decorative layer. Forinstance, the overlay layer may be transparent or translucent. However,in other embodiments the overlay layer may be opaque, as aspects of theinvention are not limited in this respect. The overlay layer may havevarious types of finishes, such as high gloss, low gloss, matte and, insome embodiments, may even include a textured surface. The overlay maybe specially adjusted as a soft formulation and polyurethane (PUR)coatings are particularly useful in such applications.

Illustrative embodiments of the invention also allow the use ofrelatively hard decorative materials as components of the decorativelayer. By way of example, in some embodiments, a real wood veneer layer,such as a veneer made of oak, among other woods, maybe used as adecorative layer. Such hard woods have not been used in prior art rollerblind covers. Illustrative embodiments may also include a stone veneerlayer as a decorative layer, or any other type of material, as aspectsof the invention are not limited in this regard.

Materials that comprise the decorative layer may be made more flexibleprior to being applied to the carrier layer. For instance, in the caseof a stone veneer, the veneer may be broken down, even until the pointwhere cracks begin to form in the veneer. In some embodiments, this maybe accomplished by placing the veneer on an intermediate layer that willhold the decorative layer together while the decorative layer is brokendown or “flexibilised”. When assembled, the intermediate layer willtypically be positioned adjacent to the carrier layer, although otherconfigurations are also possible.

According to some embodiments, cracks that may form duringflexibilization of a relatively hard decorative layer may not bevisible, particularly after the elastic overlay is positioned on top ofthe decorative layer. In other embodiments, cracking that occurs in adecorative layer may be allowed and may even be desired, particularlywhere the cracking appears to be natural. It is also possible tocounteract the visual impression of any cracks formed in the decorativelayer by dying. In one embodiment, the side of the carrier layer thatfaces towards the decorative layer may be dyed to suppress theappearance of cracking. Still, other techniques may be used to suppressthe appearance of cracking, as aspects the invention are not limited inthis respect.

Illustrative embodiments may also include a coupling agent layerpositioned between the visible surface of a decorative layer and theoverlay layer. Such coupling agent layers may help insure that thelaminate or portions of the laminate are permanently layered together,particularly in embodiments that have hard decorative layers, such asthose made of stone veneer.

Turn now to the figures, and initially FIG. 1, which shows a flat-webroller blind cover 1 that may be used to open and close an aperture 2 ofa vehicle interior equipment part 3. Aperture 2 of interior equipmentpart 3 is bordered by a pair of sliding block guides 4 and 5. Thesliding block guides extend parallel to one another along opposing sidesof the aperture 2 and serve to guide opposed edges of the roller blindcover 1.

As illustrated, sliding block guides 4 and 5 of aperture 2 liesubstantially in a common plane. Near aperture edge 6, as shown in thetop left hand portion of FIG. 1, the sliding block guides 4 and 5 curveinto a slot, although other configurations are possible. The slot of theinterior equipment part 3 receives the flat-web roller blind cover whenthe cover is positioned to provide access to aperture 2. When movinginto the slot, the roller blind cover may be placed in bending. Bendingin this manner may place an outermost surface (e.g., an overlay layer)of the roller blind cover in tension while placing an inner most portion(e.g., a carrier layer) in compression. A neutral line or plane, thatexperiences insubstantial compression or tension, may exist between theoutermost and inner most layers, as one of skill in the art mayappreciate.

Illustrated embodiments of roller blinds may also have features tofacilitate movement. As shown in FIG. 1, the roller blind has a handle 7which facilitates pushing the roller blind cover along sliding blocks 4and 5. Other configurations of handles are also possible, as aspects ofthe invention are not limited in this respect.

The roller blind cover 1 may comprise a layered laminate of variouslayers, as is shown in FIG. 2. A carrier layer 8 may provide for thestructural stability of the roller blind cover 1. As illustrated, thecarrier layer may comprise ribs that extend crosswise over aperture 2 inthe direction of arrow II shown in FIG. 1. (i.e., in a directionextending from a first sliding block guide 5 to a second sliding blockguide 4). The ribs may be joined to one another by a supporting layer 9,as is also illustrated. However, it is to be appreciated that not allcarrier layers require ribs and/or a supporting layer as shown in thefigures, as aspects of the invention are not limited in this regard. Byway of example, in some embodiments, the carrier layer may comprise asingle-ply, and in other embodiments, the carrier layer may comprisemultiple-plys.

As discussed herein, an intermediate layer 11 may be positioned next tothe carrier layer 8. The intermediate layer 11 may prove particularlybeneficial in embodiments that utilize relatively hard decorativematerials, such as stone veneers, hard wood veneers, and the like. Theintermediate layer may help hold such decorative layers together duringflexibilization prior to the decorative layer being joined to thecarrier layer.

The intermediate layer may be joined to the carrier layer throughvarious features and techniques. According to one embodiment, adhesivebonding is used to hold the decorative layer to the carrier layer,although other features and techniques are possible, as the presentinvention is not limited in this respect.

In the illustrated embodiment, a coupling agent layer 12 is positionedon the visible side of decorative layer 10. The coupling agent layer 12carries overlay 13. The overlay 13 may be transparent, although it isnot required to be, and in some cases may be translucent. The overlaymay be designed with an appropriate thickness to provide a depth effectdue to a corresponding lens action. This may convey a special appearanceto the visible surface of the decorative layer. In other embodiments,the overlay may have a thickness that allows light to be transmittedthere through, so as to illuminate the roller blind cover.

The overlay may also be made of an elastic material. In this respect,the elastic material can better accommodate any strains that the overlayis exposed to during use. It is to be appreciated that not all overlaysneed be elastic and that different embodiments may have overlays withvarying elastic properties, as the present invention is not limited inthis regard.

According to illustrative embodiments, the carrier layer 8, decorativelayer 10, and overlay layer 13 form a layered laminate with a decorativelayer sandwiched towards a central portion of the blind cover. Inparticular embodiments, the decorative layer is positioned on or nearneutral lines or planes of the roller blind cover. This allows lessflexible and even very hard materials to be used as the decorativelayer.

Having thus described several aspects of at least one embodiment of thisinvention, it is to be appreciated various alterations, modifications,and improvements will readily occur to those skilled in the art. Suchalterations, modification, and improvements are intended to be part ofthis disclosure, and are intended to be within the spirit and scope ofthe invention. Accordingly, the description and drawings herein are byway of example only.

1. A roller blind cover for an aperture in a vehicle interior, the roller blind cover comprising: a carrier layer; a decorative layer having a visible surface, the decorative layer being attached to the carrier layer; and an overlay coating that covers the decorative layer and that provides a view of the visible surface; wherein the overlay coating is permanently bonded to the visible surface and has a thickness of at least 0.3 mm.
 2. The roller blind cover according to claim 1, wherein the overlay coating is a transparent, high-gloss plastic layer with a layer thickness selected between about 0.3 mm and about 3 mm.
 3. The roller blind cover according to claim 2, wherein the elastic overlay is a soft formulation PUR layer.
 4. The roller blind cover according to claim 1, wherein the decorative layer has a layer thickness of between about 0.2 mm and about 1.5 mm.
 5. The roller blind cover according to claim 4, wherein the decorative layer is a real wood veneer layer.
 6. The roller blind cover according to claim 4, wherein the decorative layer is a stone veneer layer.
 7. The roller blind cover according to claim 1, further comprising: a coupling agent layer disposed between the visible surface of the decorative layer and the overlay coating.
 8. The roller blind cover according to claim 1, wherein the decorative layer includes an intermediate layer positioned next to the carrier layer.
 9. The roller blind cover according to claim 1, wherein the carrier layer is a multi-ply layer.
 10. A roller blind cover for a vehicle interior, the roller blind cover comprising: a carrier layer; a decorative layer; and an overlay coating; wherein the decorative layer is positioned between the carrier layer and the overlay coating and lies along a neutral axis of the roller blind cover when the roller blind cover is flexed during use.
 11. The roller blind cover according to claim 10, wherein the overlay coating has a layer thickness selected between about 0.3 mm and about 3.0 mm.
 12. The roller blind cover according to claim 10, wherein the decorative layer has a layer thickness between about 0.2 mm and about 1.5 mm.
 13. The roller blind cover according to claim 10, wherein the decorative layer comprises material selected from the group consisting of: real wood and stone.
 14. The roller blind cover according to claim 1, wherein the decorative layer includes an intermediate layer that holds the decorative layer together prior to the decorative layer being joined to the carrier layer.
 15. A method of forming a roller blind cover for a vehicle interior, the method comprising: providing a carrier layer; providing a decorative layer that comprises decorative material that is less elastic than the carrier layer, the decorative material being coupled to an intermediate layer of the decorative layer; rendering the decorative layer more flexible while the decorative material is held by the intermediate layer; and assembling the decorative layer to the carrier layer.
 16. The method according to claim 15, further comprising: assembling an overlay layer to the decorative layer.
 17. The method according to claim 15, wherein the decorative material comprises stone.
 18. The method according to claim 15, wherein the decorative material comprises real wood.
 19. The method according to claim 15, wherein rendering the decorative material more flexible comprises breaking down the decorative layer.
 20. The method according to claim 15, further comprising: positioning the decorative layer along a neutral axis of the roller blind cover. 